As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of the additive manufacturing space as a cost-efficient, reliable and flexible tool that is changing how people and companies view workflow optimization and production uptimes.One of the key areas where&nbsp;<a href="https://ultimaker.com/">UltiMaker’s 3D printing solutions</a> are being leveraged is in manufacturing components with complex geometries(including lattices or internal channels), small production runs and various tooling, jigs, and fixtures used to improve existing traditional manufacturing workflows. Let’s dive into some of the key benefits that 3D printing provides and go over some application examples:<h2>Reducing material waste</h2>When compared to traditional subtractive manufacturing methods such as milling or CNC routing, which will always result in wasted material as part of the part-shaping process, 3D printers will only use as much material as needed for the part, layer by layer. This is further compounded when taking into consideration complex assemblies that often require The ability to produce parts as needed translates directly into reduced costs associated with maintaining large inventories.<h2>Accelerated prototyping and iterations</h2>UltiMaker allows companies to exponentially increase the speed with which they can prototype, test, and refine designs. This is done without needing to rely on expensive external suppliers, which, as we’ve seen in recent years, are vulnerable to supply chain delays or interruptions.Global brands such as <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">Heineken have ensured production continuity with 3D printing</a> and decreased lead times (by as much as nine months) and production costs by 3D printing spare parts for their packaging and assembly machinery.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216290885-1733216290885.png" class="fr-fic fr-dib"><h2 id="isPasted">Eliminating tooling costs</h2>Traditional manufacturing methods often require expensive molds, dies, or tooling for each part design and more and more manufacturers are turning to 3D printing technologies to create mold inserts, assembly aids and jigs in order to streamline their production. With a market value estimated at over $73.60 billion the tooling application area is one of the fastest growing: whereas only 37% of manufacturers reported using additive manufacturing for tooling in 2019 that number grew to 57% in 2021.UltiMaker 3D printers allowed companies like <a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa to produce tools and fixtures in-house</a> and within two years see assembly-tooling cost savings increased from 70% to 95% (saving an estimated $375,000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216309556-3d-printed-wheel-protection-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">In fact, the ability to tune in and dynamically address the needs of operators working on production lines by creating various custom jigs and fixtures allows companies to streamline processes, enhance precision, and reduce the risk of human error. With more and more customer success stories such as Audi Sport’s implementation of UltiMaker’s 3D printing technology to<a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/" id="isPasted">&nbsp;create almost 200 new tools, jigs and fixtures</a> or <a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/">ERIKS’s improvement to their manufacturing process</a>, it’s evident that additive manufacturing is one of the key investments for businesses that want to stay ahead of the curve.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216327298-1733216327298.png" class="fr-fic fr-dib"><h2 id="isPasted">On-demand manufacturing</h2>UltiMaker's accessible ecosystem enables distributed manufacturing for custom or low-volume parts. Businesses print just-in-time components instead of mass-producing and storing potentially unused inventory and with over 200+ materials available on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> we’re already seeing costly metal parts like conveyor infeed worms being replaced.This is especially relevant when taking into consideration situations where certain machine parts can no longer be sourced as 3D printing allows manufacturers to reverse engineer obsolete parts and far extend the lifespan of existing legacy systems. Just ask one of our clients Trivium, who turned to 3D printing replacement parts for their automated packaging lines.If possible insert an image with the infeed worm that Trivium 3D printed or maybe grab a still from the video with the part being used in the production line?<h2>Easy to implement, easy to scale</h2>Leveraging 3D printing in production processes is also incredibly easy especially when compared to traditional manufacturing techniques that require experienced engineers and designers to create and operate the complex tooling involved which often comes with complicated specialized software that not only adds to the cost but technical expertise as well.With UltiMaker the design process is easily accessible through the various CAD softwares available (with some versions having a reduced learning curve) with the chief advantage being the ability to directly translate a CAD design into a 3D printed prototype faster than with any of the traditional methods currently available.Coupled with an unparalleled scaling capability through distributed manufacturing, a single engineer can upload 3D parts in Digital Factory making it available in any of the connected locations for localized production as the operation of the 3D printer itself is extremely simple.<h2>The future of manufacturing</h2>From rapid prototyping to on-demand production, 3D printing is reshaping the way manufacturers innovate, save costs, decrease lead times, maintain production uptimes, and minimize waste. If you’re looking to leverage the unique benefits of 3D printing, the Ultimaker Factor 4 printer combines state-of-the-art features with unmatched reliability, empowering your business to achieve more with less.

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of additive manufacturing as a cost-efficient, reliable, and flexible tool that is changing how companies view workflow optimization and production uptimes.

Benefits of 3D Printing in Manufacturing

Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing.

IMES3D: Expert Support for Industry-Level 3D Printing

<a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">CNC machining</a> is a versatile and precise manufacturing process capable of producing components with a wide range of complexity and sizes using various materials. However, it does come with size limitations dictated by various factors. Awareness of these constraints is crucial for optimising designs and ensuring that designs can be manufactured.<h2 data-counter-attr="value0">General Size Limitations of CNC Machining</h2>This section highlights several design tips and considerations that could improve part manufacturability while optimising cost and lead time. It discusses part complexity and CNC manufacturing constraints such as fillets, holes, pockets, threads, and undercuts.<h3 data-counter-attr="value1">Material Blank Size</h3>This refers to the size of the raw material used to create the finished part. Material blanks typically need to be slightly larger than the finished part’s measurements to allow for variations and to cut away rough faces of the raw material.&nbsp;For example, if the final dimensions are to be 50 x 50 x 50 mm, then a suitable material blank would be roughly 53 x 53 x 53 mm. When designing, take this into consideration by adding additional X, Y, and Z dimensions to your part and matching it to the part size limits below.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514482046-blank-size-1.png" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value2" id="isPasted">Limitation for Milled, Lathe and Drilled Parts</h3><table><thead><tr><th>Part/Feature</th><th>CNC Milling</th><th>CNC Turning</th><th>CNC Drilling</th></tr></thead><tbody><tr><td>Maximum size</td><td>The largest CNC milling machines, like the <a href="https://www.k-mm.com/large-machining/" target="_blank" rel="noopener">SNK HF-7VM vertical gantry mill</a>, have a pallet size of 3500 mm by 10000 mm, with X-axis travel of 11000 mm, Y-axis travel of 4700 mm, and Z-axis travel of 2450 mm.</td><td>The largest CNC turning centres, such as the SL 603, can handle parts with diameters up to 930 mm and lengths up to 4000 mm.</td><td>The largest CNC drilling machines, like the <a href="https://www.voortman.net/en/products/v200-plate-drilling-machine" target="_blank" rel="noopener">Voortman V200</a>, can handle plates up to 2400 mm in length, 1000 mm in width, and 60 mm in thickness, with a maximum weight of 600 kg.</td></tr><tr><td>Minimum size</td><td>Typically, the smallest feasible feature size is 0.5 mm. For practical purposes, machining features smaller than 2.5 mm in diameter is considered micro-machining and is generally avoided unless necessary.</td><td>The smallest practical diameter for turned parts is approximately 0.5 mm, with common practice starting from about 1 mm.</td><td>Standard practice for most drilling applications starts at 2.5 mm diameter for ease of production and accuracy. Although, the smallest standard drill bit size used is around 1 mm. For very small features, holes as small as 0.05 mm (50 micrometers) can be drilled, but this falls into the realm of micro-drilling, which requires specialised equipment and techniques.</td></tr><tr><td>Better alternatives for larger parts (than maximum)</td><td>• Injection molding (plastics) • Die casting, metal extrusion (metals)</td><td>• Injection molding (plastics) • Forging, casting (metals)</td><td>–</td></tr><tr><td>Better alternatives for smaller parts (than minimum)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics) • Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>• Injection molding, micro injection molding, 3D printing, micro machining (plastics) • Micro machining, electroforming, laser cutting, micro EDM, metal injection molding (metals)</td><td>–</td></tr></tbody></table><h3 data-counter-attr="value3">Feature Size Limitations: Reference Chart</h3>The following chart summarises the design guidelines associated with various features that can be made using CNC. Its purpose is to help designers optimise components for manufacturability.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514529304-diagram-cnc-machining-design-guidelines-1.webp" style="width: 100%px;" class="fr-fic fr-dib"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514573679-chart-cnc-machining-design-guidelines.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value4" id="isPasted">Size Limitations for Post-Processing</h3>The different post processing operations that can be carried out on a part depend on the size of the part. For example, larger parts often do not fit in media-blasting cabinets, therefore such parts cannot be blasted. Another example is that custom racking may be required for parts larger than 3 meters that need to be anodized, electroplated or powder coated.<table><thead><tr><th>Process</th><th>Maximum part size&nbsp;</th><th>Notes</th></tr></thead><tbody><tr><td>CNC Turning</td><td>Diameter up to 500 mm and length up to 4500 mm</td><td>Xometry uses specialized tooling, including standard 2-axis lathes, live tooling systems, multi-spindle machines, and Swiss lathes, to produce parts with milled or intricate features.</td></tr><tr><td>CNC Milling</td><td>Xometry’s partner network can typically mill parts up to X-2000 mm, Y-750 mm, and Z-600 mm.</td><td>If your part exceeds 600 mm in machinable height, it will require specialized tooling and an additional manual review for manufacturability.</td></tr><tr><td>CNC Drilling</td><td>Equipment includes upright, bench, and radial drill presses, enabling Xometry to drill holes up to 7 cm in diameter in simple and complex patterns.</td><td>The complexity of the drilling pattern and material may affect lead times and costs.</td></tr></tbody></table><h3 data-counter-attr="value5">General Manufacturing Standards</h3>Unless otherwise specified, Xometry manufactures CNC-machined components to the following standards:<ul><li>Surface Finish: The as-machined surface finish is Ra 3.2 or better, with CNC machine tool marks possibly leaving a swirl-like pattern.</li><li>Edge Treatment: Sharp edges will be broken and deburred by default. If critical edges need to remain sharp, this should be noted and specified on the CAD drawing.</li><li>Plastic Components: Clear or transparent plastics will have a matte finish or translucent swirl marks on any machined face. Bead blasting will result in a frosted finish on clear plastics.</li><li>Tolerances: Tolerances on foam or similar compressible materials cannot be guaranteed.</li></ul><h3 data-counter-attr="value6">General Tolerances</h3>Unless specifically specified by the designer, Xometry will adhere to the industry standard ISO 2768 and ISO 286 tolerances listed below:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514609862-cnc-machining-tolerances-2048x867.webp" style="width: 100%px;" class="fr-fic fr-dib">General tolerances for CNC machining start at ±0.1 mm. Tighter tolerances, defined as smaller than the general standard, can be achieved with CNC machining, reaching up to ±0.01 mm.&nbsp;Specialized setups and additional operations like reaming and grinding can allow for even tighter tolerances depending on the material and part geometry. Geometric tolerances (GD&amp;T) can be applied to the drawing, but these may increase inspection times due to the necessary tools and time for checking.While tighter tolerances improve a part’s form, fit, and function, they have drawbacks. They can lead to higher scrap rates, additional fixturing, special measurement tools, and longer cycle times from slower cutting speeds. These factors can increase pricing and lead times. Depending on the tolerance and geometry, the part cost can more than double compared to a standard tolerance.<h2 data-counter-attr="value7">General Size Limitations of CNC Machines</h2>The physical dimensions of CNC machines’ work envelopes are the main factor limiting their part size capabilities. This constraint affects all types of CNC machines, including turning, milling, and drilling. Other limiting factors include the machine’s axis travel and the number of axes.<h3 data-counter-attr="value8">CNC Machining Work Envelope</h3>The CNC machining work envelope refers to the 3D space within which the machine operates. Different machines each have their own work envelope, which limits the size of components that can be manufactured using the machine.&nbsp;The physical size of the machine, and more specifically, the X, Y, and Z directions in which the machine can move, dictates the work envelope.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514654906-1732514654906.png" class="fr-fic fr-dib">However, it is important to note that when designing components, the work envelope might be reduced due to tooling size. For example, as shown above, if the cutting bit were longer, the CNC work envelope would be smaller in the Z direction.<h3 data-counter-attr="value9">CNC Axis Travel</h3>CNC axis travel is the range over which the cutting tool or workpiece can move along the X, Y, and Z axes. This has a direct impact on the size of components that can be machined. Below is an example of a 3-axis CNC milling machine. In this case, the rail lengths dictate the distances the machining bit can move in each direction.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514681918-cnc-axis-travel-1536x1536.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value10" id="isPasted">CNC Axis Types</h3>CNC machines typically operate within 3 to 5 axes. Three-axis CNC machines move the cutting tool along the X, Y, and Z axes. Four-axis CNC machines add an additional rotation axis, which increases the complexity of the parts that can be manufactured.&nbsp;Finally, five-axis CNC machines add two additional rotation axes to the X, Y, and Z movements. The number of axes significantly affects the size and complexity of components that can be manufactured.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514699442-3-axis4-axis-5-Axis-CNC-Machining.webp" style="width: 100%px;" class="fr-fic fr-dib">Diagram of 3-axis, 4-axis and 5-axis CNC machines (Source: worthyhardware.com)<h2 data-counter-attr="value11" id="isPasted">CNC Turning Size Limitations</h2>CNC turning involves a rotating workpiece, while a single-point cutting tool removes material. The physical geometry of a CNC lathe dictates the size limitations. CNC turning machines are constrained by their centre distance, swing distances, and how the workpiece is mounted.<h3 data-counter-attr="value12">Distance Between Centres</h3>For a CNC Lathe, the distance between centres refers to the distance between the lathe headstock and tailstock. This limits the total maximum machinable length of the component that can be machined.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514792535-Technical-illustrations-01-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 data-counter-attr="value13" id="isPasted">Swing Over Bed, Cross Slide, and Gap</h3>The terms “Swing Over Bed,” “Swing Over Cross Slide,” and “Swing Over Gap” define different clearance measurements on a lathe. Swing Over Bed indicates the maximum diameter that can be machined over the bed’s longitudinal guideway.&nbsp;“Swing Over Cross Slide” is the diameter allowance over the cross slide, which is smaller than the Swing Over Bed. “Swing Over Gap” indicates a small gap allowing larger diameter parts, such as flanges, to be machined.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514816151-Technical-illustrations-06-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib">These different swing parameters affect the CNC turning diameter limits and the component length. Here’s a more detailed description:<ul><li>Swing Over Bed: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li>Swing Over Cross Slide: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered. &nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm. If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li>Swing Over Bed: The Swing Over Bed parameter represents the absolute maximum diameter of the workpiece that can be mounted. It is also important to note that the workpiece should be slightly smaller than the swing over the bed.&nbsp;</li><li>Swing Over Cross Slide: The Swing Over Cross Slide is the maximum diameter of a workpiece that can be machined when the cross slide (the part of the lathe that holds the tool post) is considered.&nbsp;The Swing Over Cross Slide is the limiting factor determining the maximum diameter of a part that can be machined using the full travel of the cross slide. For example, if a 200 mm diameter steel shaft is mounted in the lathe and you want to machine the centre of the shaft to a 100 mm diameter, your Swing Over Cross Slide will need to be large enough to accommodate the 200 mm.&nbsp;If the Swing Over Cross Slide is smaller than 200 mm, the cross slide will likely collide with the shaft. So even if the Swing Over Bed allows for a 200 mm shaft, if the Swing Over Cross Slide does not allow for 200 mm, the shaft, in this example, cannot be machined.</li><li>Swing Over Gap: The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility. The Swing Over Gap enables workpieces of larger diameters but significantly limits the length of the component and the angles at which the tool can cut. This can be achieved in some CNC machines by removing a gap block on the lathe bed. However, one should note that this differs from machine to machine and that not all CNC machines have this possibility.</li></ul><h3 data-counter-attr="value14">Mounting Method of the Workpiece</h3>In typical CNC lathe operations, the workpiece is secured in the headstock and supported by the tailstock. However, for certain tasks, the workpiece is only mounted in the headstock. In these cases, the material type and thickness determine the allowable length of the workpiece, as excessive length can cause flexing and potential issues.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514839913-Technical-illustrations-04-2048x894.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 data-counter-attr="value15" id="isPasted">CNC Milling Size Limitations</h2>CNC milling machines use rotating cutting tool to remove material from a workpiece. Milling machine size limitations are dictated by the CNC machining work envelope and tool reach.<h3 data-counter-attr="value16">CNC Machining Work Envelope</h3>The physical size of the milling machine table (X and Y) and the maximum axis (Z) travel limit the size of the workpiece. One should note that the work envelope does not denote the exact maximum size of the workpiece, and the workpiece might be further limited by the tooling.&nbsp;<h3 data-counter-attr="value17">Tool Reach</h3>The length of the cutting tool and the ability to reach different areas without interference places a size limitation on the workpiece. For example, deep features in the part could typically be limited by the tool length rather than the travel of the tool.&nbsp;To further illustrate this, if you were to have a part with narrow grooves, as in the image below, the tool length would be the limiting factor as the tool holder would not be able to move past the top face of the component, should the depth of the grooves surpass the length of the tool.&nbsp;In terms of accuracy, machines produced by Kern Microtechnik can achieve tolerances as tight as ±2 microns (±0.00007 inches).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732514866771-cnc-mill-interior-1536x865.webp" style="width: 100%px;" class="fr-fic fr-dib">Deep features in the part can typically be limited by the tool length<h2 data-counter-attr="value18" id="isPasted">CNC Drilling Size Limitations</h2>CNC drilling is used to create holes in a workpiece, and the size limitations are primarily influenced by the machine’s Z-axis travel and the length of the drill bits. Thus, it is important to ensure that the drill bit length and axis travel surpass the thickness/height of the workpiece that needs to be drilled. Another size limit is the bed size of the CNC drilling machine, which dictates the maximum length and width of the workpiece that can be drilled.

This article reviews the CNC machining size limitations, covering major constraints such as the work envelope of CNC mills and the diameter limitations of CNC-turned parts. It highlights CNC capabilities and size constraints at Xometry, available materials, and post-processing considerations.

CNC Machining Size Limitations: Everything You Need to Know

The Challenge: Optimizing Real-Time Quality Testing<a href="https://www.snaptron.com/" target="_blank">Snaptron</a>, a leading manufacturer of tactile dome switches used across industries from aerospace to medical, originally developed the Sapphire Force Testing Machine to ensure rigorous quality control. However, as technology advanced, their Director of Engineering, Kevin Albertsen, recognized the need for an upgrade. Their existing setup, which used stacked PC/104 cards on a single-board computer, was complex and costly, lacking the efficiency needed for real-time data analysis.Snaptron’s goal was clear: streamline the system to reduce expenses and increase processing speed, providing a high-quality solution without a hefty price tag.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731939443698-Sapphire_lo.jpg" style="width: 100%px;" class="fr-fic fr-dib">A Simple, Cost-Effective Solution: The Portenta H7 Lite&nbsp;Snaptron chose the <a href="https://www.arduino.cc/pro/hardware-product-portenta-h7/" target="_blank">Portenta H7 Lite</a> to upgrade the Sapphire machine. The board’s versatility allowed for rapid prototyping and iteration, reducing development time significantly. With seamless data transfer via USB and straightforward integration of digital and analog connections, Snaptron could simplify in-house PCB assembly and low-volume production.Albertsen noted the benefit of Arduino’s extensive library support and open-source resources, which accelerated the prototyping phase, freeing up resources for other projects. The Portenta H7 Lite’s cost-effectiveness also helped Snaptron manage their budget, allowing for further improvements to their system.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731939463624-ABX00045_05.unbox.jpg" style="width: 100%px;" class="fr-fic fr-dib">Expanding Market Opportunities with a New Product LineWhat began as an internal solution for quality control quickly revealed market potential. Snaptron discovered that customers also needed a similar force-displacement switch tester, prompting them to develop a commercial product based on the upgraded Sapphire. This new offering has since opened up a fresh revenue stream, showcasing how rapid prototyping can lead to unexpected opportunities.&nbsp;Curious to find out more?&nbsp;Read the&nbsp;<a href="https://www.arduino.cc/pro/case-studies-snaptron" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta H7 Lite provides an efficient and cost-effective solution for quality testing.

Snaptron optimized their quality testing machine, Sapphire, to enable faster data processing and lower costs. Leveraging Arduino’s Portenta H7 Lite, they not only improved in-house quality control but also opened up a new market segment for force-displacement testing solutions. 

Snaptron Streamlines Quality Testing with Efficient Prototyping

&nbsp;The Challenge: Addressing E-Mobility’s Compact Performance Challenge&nbsp;As e-mobility infrastructure expands, the need for advanced charging stations has introduced new technical requirements for size, reliability, and flexibility. When <a href="https://abinsula.com/" target="_blank">Abinsula</a> – an innovative company in the embedded systems and IoT solutions space – was tasked with creating a POC for a smart, wall-mounted EV charger, the company’s priority was to balance high-performance with a compact design that could be customized for future functionality.Abinsula’s experience in embedded systems positioned them well to tackle this project, but they quickly realized that most existing market solutions were either too bulky or limited in flexibility. After evaluating several options, they selected the <a href="https://www.arduino.cc/pro/hardware-product-portenta-x8/" target="_blank" rel="noopener noreferrer">Portenta X8</a> from Arduino’s Pro line and combined it with the <a href="https://www.arduino.cc/pro/hardware-product-portenta-breakout/" target="_blank">Portenta Breakout</a> to create a powerful yet compact solution that could be optimized for rapid development.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5MDQyMDc4LTE3MzE5MzkwNDIwNzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" id="isPasted" class="fr-fic fr-dii">Developing a Customizable Solution with Portenta X8Using Yocto for software customization, Abinsula was able to adapt the microcontroller to meet specific application needs while maintaining efficiency and scalability. As Paolo Doz, co-founder and CTO of Abinsula, explained, “The primary challenge was optimizing the resources of the microprocessor while planning for future functionality expansions. We were able to offload some functionalities to the Portenta X8’s onboard real-time microcontroller, ensuring the system could support additional smart features as needed, such as remote communication via 4G/Wi-Fi®.”This approach allowed Abinsula to also integrate a full human-machine interface (HMI) and control software within just one month, a major accomplishment in a field where time-to-market can provide a decisive edge.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMxOTM5MDY0NDgxLUFCWDAwMDQ5XzAyLnVuYm94LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Efficiency, Reliability, and Scalability for Future Innovation &nbsp;<iframe id="635a948941249700089f8799" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/arduino-portenta-x8?iframe=true" frameborder="0" scrolling="no"></iframe>Abinsula’s success in delivering a complete, compact POC highlights the benefits of leveraging high-performance microcontrollers for e-mobility applications. The <a href="https://www.arduino.cc/pro/hardware-product-portenta-x8/" target="_blank">Portenta X8</a>’s design offered Abinsula access to a powerful processing-to-size ratio, enabling the development of a fully operational charger that met the client’s standards for both functionality and flexibility. The project also benefited from Arduino’s Board Support Package (BSP), which allowed Abinsula to focus on application development without having to start from scratch.&nbsp;Curious to find out more?&nbsp;Read the <a href="https://www.arduino.cc/pro/case-studies-abinsula/" target="_blank">full case study on the Arduino website</a>.

The Arduino Portenta X8 combines high performance and compact form factor.

The growth of e-mobility demands versatile, reliable charging solutions that meet high standards in compact formats. Using Arduino, Abinsula developed a proof of concept (POC) for a wall-mounted, smart EV charger within a remarkable timeframe.

Abinsula: Rapid Development of a Compact EV Charger

Did you know that injection molding is transforming the medical device industry? This advanced process empowers designers to create high-quality and cost-effective products, ranging from common medical items to highly regulated devices. As products move through various stages of development—from initial prototyping to full-scale production—they must consistently meet stringent compliance, safety, and functionality standards. This ensures that each medical device aligns with critical industry requirements at every step.If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.<h2 dir="ltr">Key Considerations in Medical Injection Molding</h2><h3 dir="ltr">1. Regulatory Compliance: Meeting Corresponding Standards</h3>&nbsp;Food and Drug Administration (FDA) guidelines in the U.S. mandate rigorous tracking and documentation at every production stage to guarantee the traceability of each component. Meanwhile, Medical Device Regulation (MDR) standards in the EU emphasize consistent product safety across the device’s entire lifecycle, pushing manufacturers to follow stringent standards.Medical devices are divided into three classifications, by both FDA and MDR, based on associated risk, each with specific regulatory requirements:Class I Medical Devices: These low-risk devices pose minimal harm to users, often including items like bandages, gloves, and hand-held surgical instruments. Regulatory requirements are relatively basic, focusing mainly on general safety and quality.Class II Medical Devices: Moderate-risk devices, such as syringes, infusion pumps, and diagnostic equipment, require additional regulatory controls. These may involve special labeling, performance standards, and post-market supervision.Class III Medical Devices: High-risk devices, including pacemakers, defibrillators, and implants, require the highest level of regulatory supervision. This includes rigorous premarket approval, extensive testing, and clinical trials to confirm safety and effectiveness.For instance, a diagnostic device used for detecting infectious diseases needs each plastic component to withstand various sterilization processes without degrading or releasing harmful substances. Even minor contamination could compromise the device’s accuracy or pose risks to patients, underscoring the importance of these strict regulatory standards. Ensuring regulatory compliance is essential in medical injection molding, as incorrect categorization or non-compliance can lead to delays, increased costs, and a longer time to market.<h3 dir="ltr">2. Certifications: Guaranteeing Quality and Safety</h3>Certification is a standard, ensuring the products meet or exceed industry requirements. Key certifications in the medical industry include:ISO 13485: This certification ensures a quality management system is in place, maintaining consistency across production batches. For example, if producing IV systems or ventilators, ISO 13485 certification is critical.ISO 10993: For parts that come in direct contact with bodily fluids or tissues, ISO 10993 ensures biocompatibility. This certification is essential when manufacturing parts such as catheter tips or implantable device housings, where material safety directly impacts patient health.ISO 14644: This cleanroom certification is crucial for preventing contamination. A cleanroom-certified facility, for instance, can safely produce surgical device components that require a sterile environment, ensuring they meet hospital and surgical standards.<h3 dir="ltr">3. Material Selection: Biocompatibility and Durability</h3>Choosing materials for medical applications involves considerations beyond standard injection molding. Examples include:<ul><li dir="ltr">Polycarbonate (PC): Due to its strength and transparency, often used for housing devices requiring internal visibility, such as blood analyzers.</li><li dir="ltr">Polyethylene (PE):&nbsp;Known for chemical resistance and flexibility, PE is used in IV bags and tubing, ensuring durability and low moisture absorption.</li><li dir="ltr">Polypropylene (PP): With strong impact resistance and sterilization stability, PP is used in syringes and medical containers, offering long-term reliability.</li><li dir="ltr">Polystyrene (PS):&nbsp;Widely used for disposable labware, PS offers rigidity, transparency, and easy sterilization, making it suitable for laboratory applications.</li><li dir="ltr">Polyether Ether Ketone (PEEK):&nbsp;Widely used in implantable devices due to its strength, stability under sterilization, and biocompatibility.</li><li dir="ltr">Thermoplastic Elastomer (TPE):&nbsp;Its flexibility makes it suitable for soft-touch surgical instrument handles that withstand repeated sterilization.</li></ul>Every material choice has specific trade-offs. For instance, while PE and PP are cost-effective and chemically resistant, they might lack the strength needed for parts exposed to high-stress environments. Therefore, understanding these nuances helps in material selection, optimizing for both performance and cost.<a href="https://www.rpworld.com/en/resources/blog/what-materials-work-best-for-your-medical-device-development.html">&nbsp;Click Here</a> to explore more material choices.<h3 dir="ltr">4. Prototyping to Production: Ensuring a Smooth Transition</h3>Transitioning from prototypes to full-scale production isn’t always straightforward. During prototyping, designs may feature thinner walls or more complex geometries than standard injection molding processes can easily reproduce at scale. For example, a prototype with sharp corners that’s achievable created by the vacuum casting process, but requires design optimization, such as adding radii, and adding draft angle for efficient injection molding without sacrificing quality.When scaling up, an experienced injection molding partner with expertise and capabilities can help optimize these designs for manufacturability without compromising on quality. At RPWORLD, we assist clients in this crucial transition, helping optimize part design, select the most suitable materials, finishing options and more to support efficient and regulatory-compliant production.<h2 dir="ltr">How RPWORLD Injection Molding Accelerates Your Medical Development</h2>At RPWORLD, we integrate material expertise, one-stop manufacturing services, in-depth DFM analysis and ISO-certified process to help bring medical devices to market faster. Our services cover the entire lifecycle—from prototyping to mass production—tailoring to meet the unique needs of each medical device.Our Injection Molding Services Include:<ul><li dir="ltr">20+ years of experience in medical device injection molding, from prototyping to end-use production.</li><li dir="ltr">Mold flow analysis, and in-house tools design and fabrication.</li><li dir="ltr">Design for Manufacturing (DFM) guidance, including design optimization, material selection, finishing selection and more to avoid costly rework and save time up to 80%.</li><li dir="ltr">A wide variety of post-processing options to perfect your parts.</li><li dir="ltr">State-of-the-art quality inspection equipment and stringent quality control including real-time process monitoring to ensure consistency.</li></ul>

Photo by National Cancer Institute on Unsplash

If you’re considering taking the next step in medical injection molding, this article will guide you through 4 key considerations in medical injection molding, from understanding device classifications and regulations to selecting suitable materials and preparing your design.

From Prototype to Production - 4 Critical Considerations for Safe and Compliant Medical Injection Molding

<a href="https://www.apsx.com/" target="_blank" rel="noopener noreferrer">APSX machines</a> provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets. Here’s how they contribute to these areas:1. Sustainability through Resource OptimizationAPSX machines are engineered to support sustainable manufacturing practices by incorporating features that minimize resource consumption and waste generation. Here are the key aspects that enhance sustainability:<ul type="disc"><li>Precision Engineering with Minimal Waste: APSX machines employ advanced CNC machining techniques and high-precision controls that optimize material usage. These machines reduce excess material usage, leading to less waste and more efficient use of raw materials.</li><li>Energy-Efficient Operations: The machines are equipped with energy-efficient drives and smart motor controls that reduce power consumption during idle periods and optimize energy use during production. This efficiency lowers the overall carbon footprint of manufacturing processes.</li><li>Reduced Tooling and Maintenance Requirements: APSX machines often require fewer tool changes and less maintenance compared to traditional manufacturing setups. This results in a lower consumption of consumables and extends the lifespan of parts, contributing to less industrial waste and a more sustainable production environment.</li><li>Support for Eco-Friendly Materials: These machines can handle a wide range of materials, including biodegradable and recycled composites, supporting the use of eco-friendly alternatives. Manufacturers can experiment with sustainable materials without compromising on quality or precision.</li></ul>2. Small-Batch Production for Niche MarketsAPSX machines are particularly well-suited for small-batch production, making them an ideal solution for niche markets that demand high customization and lower production volumes. Here’s how APSX machines help:<ul type="disc"><li>Flexible Production Capabilities: APSX machines are designed with versatility in mind, allowing manufacturers to quickly switch between different product configurations without the need for extensive retooling. This flexibility is crucial for producing small batches of customized products or catering to specific client requirements.</li><li>Cost-Effective for Low-Volume Runs: Traditional manufacturing equipment often incurs high setup costs, making small-batch production economically unfeasible. APSX machines, with their lower upfront costs, modular configurations, and minimal setup requirements, enable manufacturers to achieve profitability even with low-volume runs.</li><li>Shorter Lead Times: With advanced CNC and additive manufacturing capabilities, APSX machines reduce production times and enable rapid prototyping, making it easier to test and validate new designs. This agility is essential for niche markets that value speed and flexibility in meeting unique customer needs.</li><li>Customization with High Precision: Niche markets often require highly specialized products with unique specifications. APSX machines can execute complex geometries and fine detailing with high accuracy, ensuring that even small production runs meet the exact standards of quality and design.</li></ul>3. Supporting Sustainable Product DevelopmentAPSX machines allow businesses to experiment and iterate on sustainable product designs with minimal material investment. This makes it easier for companies to refine eco-friendly product offerings without incurring the high costs typically associated with traditional prototyping and production methods. For manufacturers targeting environmentally-conscious markets, this capability supports the development of products that align with sustainability goals.4. Enabling On-Demand ManufacturingIn niche markets, demand can be unpredictable and fluctuate widely. APSX machines enable an on-demand manufacturing model, where production is initiated based on real-time orders rather than maintaining high levels of inventory. This approach minimizes overproduction and reduces inventory waste, further contributing to sustainable practices.#injectionmolding #cncmachining #prototyping #sustainability&nbsp;

APSX machines provide a strategic advantage for manufacturers looking to achieve sustainability and cater to small-batch production, particularly for niche markets.

Sustainability and Small-Batch Production with APSX Machines

From accelerating production timelines to ensuring unmatched quality control, the adoption of APSX machines can redefine operational performance for businesses of all sizes from an inventor/entrepreneur alone to global companies around the world.1. Revolutionizing Manufacturing Efficiency with AutomationAPSX machines are built with automation at their core, reducing manual intervention and optimizing every stage of production. They incorporate CNC capabilities, allowing for precise execution of complex parts and simple injection molding process for making real plastic functional parts instead of fragile 3D printed parts. This translates into shorter production cycles, lower lead times, and a dramatic reduction in product development and production costs.By integrating APSX machinery, businesses can achieve substantial efficiency gains, minimizing downtime due to long lead times and ensuring continuous production. These systems also enable manufacturers to schedule operations 24/7, maximizing output and enhancing the overall production capacity without compromising quality.2. Scalable Solutions Tailored for SMEsFor small and medium enterprises (SMEs), balancing capital investment with production output is critical. APSX machines provide a cost-efficient solution, featuring modular designs that scale with business growth. Unlike traditional machinery, APSX systems have a low total cost of ownership (TCO), owing to their energy-efficient operations, minimal maintenance requirements, and a reduced need for expensive tooling.This scalability ensures that SMEs can start with a smaller setup and expand their manufacturing capabilities as demand increases, without the need for a complete overhaul of their production infrastructure. The flexibility and affordability of APSX solutions make them ideal for companies looking to innovate while maintaining profitability.3. Enhanced Versatility Across Multiple SectorsOne of the standout features of APSX machinery is its adaptability to various manufacturing needs. From automotive components to medical device production, these machines are engineered to handle a broad spectrum of materials, including metals, plastics, and composites. This versatility is supported by advanced programming options and customizable mold designs that allow for seamless transitions between different product specifications.For industries requiring precision and consistency—such as aerospace and electronics manufacturing—APSX machines provide unparalleled control over complex geometries and intricate detailing, ensuring that each output meets stringent industry standards.4. Accelerated Prototyping for Rapid Product DevelopmentIn today’s competitive market, speed-to-market is a critical success factor. APSX machines empower businesses to rapidly prototype new designs using subtractive and additive manufacturing techniques. By leveraging CNC milling or 3D printing capabilities, companies can iterate quickly on product designs, making necessary adjustments in a fraction of the time required by traditional methods.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1727718506442-27.09.2024_12.21.09_REC.png" style="width: 100%px;" class="fr-fic fr-dib">This rapid prototyping capability reduces the time between concept and market-ready product, enabling manufacturers to respond swiftly to consumer feedback and changing market trends. Moreover, the ability to produce functional prototypes allows for comprehensive testing, ensuring that final products meet all performance and reliability criteria before mass production.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzI0NTY1LUFQU1gtUElNX0hvbWVQYWdlXzEwMDAuSlBHIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">5. Precision Engineering for Superior Product QualityPrecision and repeatability are the hallmarks of APSX machinery. Using state-of-the-art software and premium components, these machines deliver exceptional accuracy, maintaining tight dimensional control even in high-volume production runs. This capability is essential for industries where product uniformity and reliability are non-negotiable, such as medical device manufacturing and precision engineering.APSX machines utilize closed-loop feedback systems, ensuring real-time adjustments that prevent deviations and guarantee that each part produced is identical to the next. This high degree of precision reduces the incidence of defective products, enhances quality assurance, and minimizes material waste, ultimately leading to improved profitability and sustainability.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NzE4MzUwODEwLXN3aXNzLWJhbm5lcl8xLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">6. Sustainability Through Resource EfficiencyEnvironmental responsibility is becoming a priority for manufacturers worldwide. APSX machines contribute to sustainability by incorporating energy-efficient drives and low-waste manufacturing techniques. With programmable precision, these machines optimize material usage, minimizing scrap rates and reducing the overall carbon footprint of the production process.In addition, the adoption of APSX technology aligns with green manufacturing practices by supporting the use of recyclable materials and facilitating the remanufacturing of worn components, extending the lifecycle of products and reducing industrial waste. #injectionmolding #cncmachining #prototyping #sustainability

APSX machines represent a significant breakthrough in modern agile manufacturing, designed to boost efficiency with easy setups, precision for injection molding over 3D printing, and scalability across diverse industrial sectors due to their low initial investment and small sizes. 

Top Benefits of Leveraging APSX Machines for Industrial Optimization

Sensors and actuators are essential elements of industrial systems, instrumental to any application that requires automated control. Sensors measure changes in the environment while actuators control physical changes, with both devices serving as mediator between the physical environment and the electronic system where they are embedded.Raspberry Pi provides general purpose header pins that can be connected to sensors, making the innovative low-cost board a popular and valuable choice for engineering prototypes. However, Pi’s GPIO pins are designed for driving low current devices such as LEDs, so is it possible to connect to the I/O necessary for industrial environments?The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control:<ul><li>Temperature: Both contact and contactless sensors can be used to measure temperature.</li><li>Photoelectric: Ideal for counting specific objects using light or lasers.</li><li>Button and Switches: Simple human inputs used to control the functioning of a system.</li><li>Dial: Simple human input providing analogue/continuous control of a signal over a range of values.</li><li>Pressure: Useful for detecting blockages, and signalling when a system needs servicing.</li><li>Vibration: Often the first sign of a problem, sensors that detect changes in vibration are great for predictive maintenance.</li><li>RFID: Used to track and/or locate devices, personnel, and/or equipment.</li><li>Inductive: The typical automation sensor, alerting to the presence of metal.</li><li>Power Consumption: Key to understanding energy usage, also a useful signal for predictive maintenance</li></ul>Industrial sensors typically require 12-24V power and signal changes using the same voltage. Raspberry Pi’s GPIO input circuitry can be driven to either 3.3V (high) or 0V (low). This means that whilst a 12V water flow sensor might initially work hooked straight up to a Raspberry Pi, in long- term industrial projects the incompatibility of the currents will almost certainly cause problems.<h2>Does this mean Raspberry Pi can’t be connected to industrial sensors beyond a prototype?</h2>Connecting a sensor to Raspberry Pi directly often means stripping the sensors wiring and soldering the cable to the correct GPIO pin. The 12 or 24V of an industrial sensor will then be driven straight to the Pi with nothing in the way to protect Pi internal circuitry, including the processor. By adding extra circuitry as a buffer between the input pin and the Pi, it’s possible to extend the processor’s source/ sink current capabilities, and prevent excessive power dissipation in the chip.<h2>Breadboards and the Factory Floor</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2MTkzNzgzLXZpc2hudS1tb2hhbmFuLXZ0Zzh0QWRvV1ZRLXVuc3BsYXNoLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Photo by Vishnu Mohanan on UnsplashBreadboards are solderless circuit boards that can house the most complex circuits, making them an invaluable option for prototyping. The impermanence afforded by the boards allows you to build and test multiple circuits without the need to constantly solder rewired connections. In this way, breadboards are great for testing new parts, integrated circuits and for troubleshooting.Some circuits will require a considerable amount of space, another feature of breadboards that makes them useful tools in industrial prototyping is the ability to extend the surface size by connecting multiples together.While breadboards can go a long way in adapting Raspberry Pi for industrial applications, certain considerations may be prohibitive to deploying such a prototype directly to a factory environment. The completed set-up is undeniably still a prototype; the connections, whilst providing industrial I/O options, are not optimised for the rigours of the factory floor.&nbsp;<h2>Industrialised Pi</h2>Powered by Raspberry Pi, Brainboxes BB-400 is a smart industrial controller that allows prototypes to be deployed straight into industrial environments.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI3NjY2NTk4MTgyLWJiLTQwMC1waTMtMTAyNHg2ODEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Rather than adding protection to the GPIO using a breadboard and external circuitry, the built in circuitry of the BB-400 allows 12V and 24V sensors to be directly connected to the IO lines without the need to add additional components to step down the voltages.<h2>Never Lose a Configuration with Removable Terminal Blocks</h2>Using a screwdriver to connect sensors’ wires/cables into the embedded terminal blocks means that the circuitry doesn’t require soldering to create strong and secure connections, allowing multiple reconfigurations. As the terminal blocks can be unplugged, it’s easy to take the module out without affecting any of the pre-wired terminals.As a single misplaced component leg can cause the whole circuit to malfunction or even cease to function at all, another useful feature of the terminal blocks is their numbering. It’s a lot easier to decipher the correct connection when you eliminate the need to count down a row of tiny header pins!The BB-400 has 8 onboard digital I/O and multiple connectivity options: RS232/422/485 Serial port,Bluetooth, Wi-Fi and Dual Ethernet, making it usable straight out of the box without the need for any add-on units. Packaged in an industrial DIN rail enclosure, the BB-400 is the perfect solution for deploying a Raspberry Pi prototype straight onto the factory floor.<a href="https://offer.brainboxes.com/prototyping-on-a-pi" target="_blank" rel="noopener noreferrer">Download the Prototyping with Pi E-book here. </a>

The type of sensors you’ll need to connect to your Pi will depend on the particular job your prototype is designed to perform. In manufacturing, the most common processes are concerned with monitoring and control

Unlock Industrial Prototyping: Your Guide to Connecting Industrial Sensors to Raspberry Pi

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.EV manufacturers need to innovate more quickly than ever to stay competitive in a market that’s expected to grow rapidly. According to<a href="https://www.grandviewresearch.com/industry-analysis/electric-powertrain-market" target="_blank">&nbsp;Grand View Research</a>, the global electric powertrain market was valued at $83.30 billion in 2022 and is projected to grow at a compound annual growth rate (CAGR) of 15.3% through 2030.<h2 dir="ltr">Manufacturing Challenges in EV Motors, Batteries, and ECUs</h2>At the heart of this rapid shift towards electric vehicles are three critical components: EV motors, batteries, and ECUs (Electronic Control Units). These elements form the backbone of every electric vehicle, powering its movement, optimizing energy efficiency, and managing complex operations. However, as the industry grows, so do the manufacturing challenges associated with these components.<h3 dir="ltr">EV Motors</h3>The design of EV motors is crucial for efficiency. Manufacturers now use thinner stamped lamination sheets (between 0.15 mm and 0.3 mm) to reduce power consumption, but producing these sheets requires extreme precision, especially when handling intricate profiles and sharp corners. Additionally, the need for lightweight materials and complex cooling systems to prevent overheating further complicates motor manufacturing. For mold makers, these factors demand high accuracy to ensure performance and keep assembly costs low.<h3 dir="ltr">Batteries</h3>Batteries serve as the heart of every EV, where power storage and management are critical to vehicle performance. Several production challenges arise:<ul><li dir="ltr">Efficient cooling systems are needed to prevent overheating during use.</li><li dir="ltr">Precise use of materials such as silicon carbide and ceramics is required for durability and heat resistance.</li><li dir="ltr">Perfectly sealed shields are essential to prevent leaks and sediments, which can compromise battery efficiency and safety.</li><li dir="ltr">The growing demand for smaller, lighter battery designs calls for highly accurate mold tooling and efficient production methods.</li></ul><h3 dir="ltr">ECUs (Electronic Control Units)</h3>These units manage critical functions such as power distribution and motor control. Producing intricate micro molds for ECUs is a significant challenge, as even small deviations can affect performance and safety. Manufacturers must ensure precision and consistency, particularly in customized production.<h2 dir="ltr">How Rapid Prototyping Solves These Manufacturing Challenges?</h2>Automotive Manufacturers need solutions that increase efficiency, reduce costs, and allow for greater customization. Rapid prototyping has become a key tool to address these challenges.<ul><li dir="ltr" style="font-weight: bold;">Digital Manufacturing and Quality Control</li></ul>Rapid prototyping uses advanced digital manufacturing techniques to ensure precise production of complex components like thinner stamped lamination sheets for EV motors. By leveraging 3D printing and CNC machining, manufacturers can quickly create and test motor designs, optimizing for both efficiency and durability. This process allows for rapid iteration of complex cooling systems to prevent overheating, ensuring that all parts meet the required specifications.<ul><li dir="ltr" style="font-weight: bold;">Low-Volume, High-Customization Production</li></ul>Battery production often requires customized solutions for challenges like efficient cooling and ensuring perfect seals. Rapid prototyping enables manufacturers to produce small batches of custom battery modules or cooling components at a lower cost. This flexibility allows for frequent design adjustments to meet the evolving demands for smaller, lighter batteries without costly retooling or manual interventions. It also ensures that material precision and sealing are tested and verified before large-scale production.<ul><li dir="ltr" style="font-weight: bold;">Supplier Integration for Streamlined Production</li></ul>For EV manufacturers, working with a single supplier from prototype to full-scale production simplifies the process. Rapid prototyping allows seamless supplier integration, reducing the time and costs associated with switching suppliers. This ensures consistent quality and faster production, especially when developing critical components like motor housings and battery enclosures.<ul><li dir="ltr" style="font-weight: bold;">&nbsp;Accelerated Time-to-Market</li></ul>In ECU development, where micro molds with extreme precision are essential, rapid prototyping accelerates the time-to-market by allowing manufacturers to quickly design, test, and refine intricate components like ECU casings and micro connectors. This ability to rapidly iterate and test designs ensures that production can proceed without long delays, meeting the stringent requirements for safety and performance in the fast-evolving EV market.<h2 dir="ltr">RPWORLD’s On-demand Manufacturing Solutions for EV Component Innovation</h2>RPWORLD offers a wide range of manufacturing services, including CNC machining, injection molding, vacuum casting, and a variety of finishing options, providing automotive customers the flexibility to select the best methods for developing and producing components. Whether for traditional ICE vehicles or EVs, our services enable rapid prototyping with the highest precision and shortest lead times. Our expertise in electric vehicle component development is extensive, offering specialized solutions for motors, batteries, and ECUs, such as:<ul><li dir="ltr">Precision motor housings and lamination components for optimal efficiency</li><li dir="ltr">High-quality battery pack enclosures and cooling system components</li><li dir="ltr">Custom-designed battery module connectors and management system housings</li><li dir="ltr">Detailed ECU casings and intricate micro connectors for zonal control units</li><li dir="ltr">Thermal management parts for both battery and ECU systems to ensure efficient heat dissipation</li></ul>As the automotive industry continues to shift toward electric vehicles, RPWORLD is proud to serve as a trusted partner, providing rapid prototyping solutions that help drive innovation and accelerate the transition to an all-electric future.<a href="https://www.rpworld.com/en/about-us/contact-us/" target="_blank">&nbsp;Let’s work together</a> to bring your EV projects to life.

From the days when ICE cars saw minor updates every three years and major redesigns every five, we’ve shifted to an era where new EV models are released annually. The rapid evolution of electric vehicles is not only energizing the market, but also intensifying competition among manufacturers.

4 Ways Rapid Prototyping Accelerates Innovation in New Energy Vehicles

Every day, millions of glass bottles, cans and PET containers run through a Krones line. <a href="https://www.krones.com/en/index.php" target="_blank">Krones</a> is a leading manufacturer of complete systems for breweries, beverage bottlers and food producers. Its production lines fill packages, add labels, and perform quality control on the products. As a global market player in the beverage and packaging industry, Krones provides comprehensive solutions that customers, such as Coca-Cola and Heineken, rely on heavily.<iframe width="640" height="360" src="https://www.youtube.com/embed/fdjkrFzIk84?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h2>When every second counts</h2>The production lines of Krones are extremely efficient in producing, filling, and packing products. But with these massive production volumes, every second counts. When a machine is not running, companies could lose out on significant revenue. This is why it’s critical to have the highest possible uptime. While Krones machines are extremely reliable, every part will wear and might need replacing for optimal performance. While most customers keep a selection of spare parts, it’s unrealistic, expensive and unsustainable to keep a large stock of spares as many of these parts will never be used. Every part needs to be produced, checked and shipped.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjM5ODg2LUtyb25lcy11c2VyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Every part produced for a Krones machine is checked for the highest quality.<h2 id="isPasted">3D printing at Krones</h2>To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. Outsourcing the production of prototypes is very expensive and often could take weeks. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases. By prototyping faster, Krones tested and iterated on their designs faster, ensuring that new parts performed better and lasted longer. This has helped customers with more reliable machines, higher uptime and a smaller environmental footprint.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNjY3MDU3LUtyb25lcy1hcHBsaWNhdGlvbi02LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">3D printing in-house has enabled Krones to produce critical parts for their machines.<h2 id="isPasted">Benefits of 3D-printed parts over traditional parts</h2>By testing prototypes of parts, Krones discovered that 3D-printed parts met the performance requirements of many final parts. Not only are 3D-printed parts cheaper to produce, their reduced weight is also often a big benefit. Parts can also be printed in different materials depending on the need for different properties, such as more flexibility or ESD-safety. This enabled Krones to shift 3D printing from simply an internal tool to a new revenue stream as an added service for customers.<h2 id="isPasted">On-demand production parts for customers, anywhere</h2>When storing a huge stock of spare parts is not desirable or spare parts are needed urgently, you need to be able to acquire parts fast once they are needed. Ordering and shipping parts can take days to weeks, while local stocks or customs can make certain locations difficult to guarantee certain quality service. 3D printing on location offered a huge opportunity for Krones and its customers.When customers need a spare part for a machine, they can order the part in the Krones.shop - the online customer touchpoint. If the spare part is able to be 3D-printed, it will be produced locally on UltiMaker printers. This way, customers won’t need to store huge quantities of spare parts in all of their locations. They can simply print the parts they need, while minimizing downtime of their production lines drastically. This process reduces part delivery from weeks to days, or even hours.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzAxMjU3LUtyb25lcy1hcHBsaWNhdGlvbi0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Printing parts on-demand have shown to reduce costs and improve operational efficiency.<h2 id="isPasted">Quality assurance of 3D printed parts</h2>The functionality and durability of a part depends on many factors. While the design of a part might be the same, the choice of materials and production settings have a great influence on the performance. Krones defines the right materials and print settings for every part. When a customer orders a replacement part for their Krones line, the spare will be 3D printed using customized settings and Krones-specific materials. This results in a certified part that is sure to meet the quality standards required. Krones quality can only be found where it says Krones Quality on the label.<h2>A flexible 3D printing solution that meets strict quality and IT standards</h2>Choosing the right 3D printing ecosystem can be very challenging. For Krones, UltiMaker was the right choice thanks to its agile, open and secure solutions. UltiMaker 3D printers have been known for their reliable and consistent quality. UltiMaker’s software comes with print profiles for hundreds of materials and brands, making it easy to pick the right material for the job. However, Krones was in need of a custom material with extremely specific requirements. Thanks to UltiMaker’s open materials platform, Krones was able to develop its own material for its own parts and create reliable print profiles.UltiMaker’s professional software also helped Krones to meet the data protection standards set by IT. Print jobs on location are securely monitored by Krones through a custom software solution, assuring customers of the quality of the print job. Regular software and firmware updates also ensure Krones utilizes a future-proof 3D printing ecosystem.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzI4OTM2LUtyb25lcy1hcHBsaWNhdGlvbi00LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">UltiMaker's 3D printing ecosystem and open materials platform allowed Krones to customize their solutions to meet customer demands.<h2 id="isPasted">Moving forward with the Factor 4</h2>Krones has been printing in over 10 locations using a large fleet of nearly 50 UltiMaker S5 and UltiMaker S7 printers. Adding the recently launched UltiMaker Factor 4 to its repertoire has brought new possibilities to Krones.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI2MDQxNzUzMDYyLUtyb25lcy1GYWN0b3ItNC0xLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">The addition of UltiMaker's new Factor 4 3D printer has enabled Krones to provide more support to its customers.Johannes Karl, Head of Customer 3D Solutions, at Krones, stated:<blockquote>We’re excited about the potential of the Factor 4. The Factor 4 has taken our capabilities to the next level. With support for stronger and more durable materials, we're able to produce parts that are not only tougher but also offer greater flexibility with softer materials.</blockquote>The new UltiMaker Factor 4 has a direct drive printhead. This makes printing soft materials easier and even more reliable. Because of the direct drive, the Factor 4 enables users to print parts in even softer and grippier materials. These features bring new opportunities for example for grippers, flexible parts or protective parts.The new UltiMaker Factor 4 can also print at even higher temperatures, in a better isolated build chamber. This enables engineers to use materials such as UltiMaker’s PPS CF. A material that can easily substitute for PEEK or even steel.The new features of the Factor 4 push innovation at Krones even further, helping them to deliver even more service to their customers.Bernd Baldauf, Head of Global eBusiness - Global Digital Content Management - Global 3D Customer Solutions, at Krones, concluded:<blockquote>Our goal is to grow closer to our customers and become their solution partner. Providing rapid, high-quality parts on demand, and continuously improving our service offerings in Krones quality. With UltiMaker's innovative solutions, we're well on our way to achieving that.</blockquote>

Printing parts on-demand have shown to reduce costs and improve operational efficiency.

To help customers get even more uptime, develop parts faster or create emergency spare parts, Krones turned to 3D printing. With the use of UltiMaker 3D printers, prototypes were able to be produced in a day, or even in hours in some cases.

Krones: Optimized 3D-printed parts & spares for customers anywhere

<h3 dir="ltr">The Importance of Prototyping in PCB Development</h3>Prototyping is a crucial step to test and validate design before mass production. In the context of PCBs, prototyping helps identify issues in the board layout such as incorrect trace connections, and checks if the design can carry out its primary functions.<h3 dir="ltr">The Challenges of Traditional PCB Prototyping</h3>For years, traditional PCB prototyping methods played a key role in electronics development. However, these methods come with its fair share of challenges that hinder efficiency, cost-effectiveness, and speed. For many small and mid-size businesses, especially startups, setting up traditional PCB prototyping equipment can be prohibitively expensive. Outsourcing to third-party manufacturers is another option, but it comes with its own set of challenges. Coordinating with external suppliers can result in long lead times and additional costs considering each design iteration requires programming their machines with your updated design files. On top of that, suppliers usually impose minimum order quantities, which means you could end up paying for more boards than you need.<h3 dir="ltr">A New Approach to Rapid PCB Prototyping</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1OTgwMTk3NTc3LWxhcmdlVm9uZS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Image: Voltera V-One desktop PCB printer (Source:&nbsp;<a href="https://www.voltera.io/v-one?utm_campaign=Wevolver&utm_source=Blog&utm_content=V-One" target="_blank" rel="noopener noreferrer">Voltera</a>)In today’s competitive market, getting your product to market quickly is crucial. That’s why rapid prototyping techniques are needed to stay ahead of the competition. The <a href="https://www.voltera.io/v-one?utm_campaign=Wevolver&utm_source=Blog&utm_content=V-One" target="_blank">Voltera V-One</a> desktop PCB printer is a game-changer in this space. It’s compact, cost-effective, and speeds up your product development process. In this article, we’ll dive into the V-One’s features and show you how to make the most of its capabilities so you can hit the ground running with this innovative tool.<h1 dir="ltr">What is the Voltera V-One?</h1>If you’re not familiar with PCB printers, picture them as similar to 3D printers, but instead of creating physical objects, they print intricate circuit patterns onto boards. Just as a 3D printer builds up layers of material to create a three-dimensional object, a PCB printer lays down conductive ink or other materials layer by layer to form the electrical pathways on a circuit board.<h3 dir="ltr">Why Choose the V-One for Prototyping?</h3>The V-One offers massive advantages over traditional prototyping processes by integrating PCB printing, drilling, and solder paste dispensing into a single system. This combination cuts iteration time from days and weeks to mere hours, allowing you to identify design errors early and reduce time to market.The device supports an aligned printing feature, which comes in handy for printing on substrates with pre-existing features. This means you can print on popular development boards like Arduino and Raspberry Pi to create useful add-ons. It’s also perfect for creating double-sided PCBs without any hassle.The V-One is a plug-and-play machine with user-friendly software. It is powerful enough to be trusted by experts at NASA, yet straightforward enough for a student to quickly learn. Whether you’re a seasoned engineer or just starting out, the V-One is designed for all skill levels.Prototyping your PCBs in-house has the added perk of keeping your intellectual property safe. When you outsource PCB prototyping, there’s a chance of exposing your designs to unauthorized use, especially if you’re working with suppliers in areas where IP protection isn’t as strong.<h1 dir="ltr" id="isPasted">Double-Sided PCB Prototyping with the Voltera V-One</h1>In this tutorial, we’ll walk through the process of creating a double-sided PCB using the Voltera V-One, using a punk console as our example.Step 1: Prepare and Upload Your Gerber FileYou can design your PCB layout using a variety of computer-aided design (CAD) software. The next step is to export your designs in Gerber files. Depending on your software of choice, Voltera offers a detailed Gerber export guide for KiCad, OrCAD, EAGLE, and Altium. Open the V-One software and upload your Gerber file. The software will automatically calculate the tool paths required for your design.Step 2: Set Up the Printing SurfaceSince we’ll be drilling to make a double-sided board, place a sacrificial layer underneath the PCB to protect the bed from any potential damage. Secure the board and sacrificial layer in place by clamping them down onto the printer's bed.Step 3: Surface MappingAttach the proximity probe to the V-One. The software will map the board in XYZ space, preparing it for accurate drilling and trace printing.Step 4: DrillingReplace the proximity probe with the drill head. Begin by drilling small holes for vias. Next, drill larger holes for through-hole components. The software will prompt you to change the drill bit as needed.Step 5: Print Traces on the Top SideAfter drilling, clean off any debris from the board’s surface to ensure smooth printing. Swap out the drill head for the dispenser, and allow it to calibrate. Start printing the conductive traces on the top layer. If you notice any mistakes, the V-One offers a selective printing option that allows you to fix specific areas.Step 6: Curing the Top SideAfter printing, remove the sacrificial layer. Flip the board over and rest it on the baking ledges of the clamps. The curing process takes about 40 minutes. Let the board cool down afterward.Step 7: Print Traces on the Bottom SideOnce the top side has cured, flip the board over to prepare for the bottom side printing. Use the aligned print option in the software, utilizing drilled holes to ensure the top and bottom sides are perfectly aligned.Begin printing the conductive traces on the bottom side. Cure it using the same procedure as explained in step 6.Step 8: Add Rivets to Connect SidesAfter both sides are printed, use rivets to connect the top and bottom sides at the drilled holes, ensuring proper electrical connectivity between the sides.Step 9: Dispense Solder PasteClamp the board back onto the printer, snap in the proximity probe, and remap the board to ensure accuracy. Replace the probe with the dispenser, this time with a cartridge of solder paste installed, rather than conductive ink. Dispense solder paste onto the designated pads for precise application.Step 10: Reflow and Solder ComponentsPlace your components on the board and use the heated bed to reflow all surface-mount components in a single step. For through-hole components, use a soldering gun and solder wire to manually solder them in place.<h2 dir="ltr">Case Study: Creating a Wearable Device for Robotic Hand Control</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1OTgwMzI5NzY3LXZvbHRlcmFfYXJ0MS5qcGVnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Image: Printed Strain Gauges on TPU laminated on a Glove for Remote Hand Control (Source:&nbsp;<a href="https://www.voltera.io/application-whitepapers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" target="_blank" rel="noopener noreferrer">Voltera</a>)Read how Voltera’s V-One PCB printer and NOVA materials dispensing system enabled a second-year undergrad studying Mechatronics, Robotics, and Automation Engineering at the University of Waterloo to design and build a fully functional robotic hand that mimics the movements of an operator wearing a control glove – in just two months.&nbsp;<a href="https://www.voltera.io/application-whitepapers/printing-strain-gauges-tpu-laminated-glove-remote-hand-control" target="_blank">Printing Strain Gauges on TPU laminated on a Glove for Remote Hand Control</a><h2 dir="ltr" id="isPasted">Industries and applications where the V-One has made a significant impact</h2>Voltera V-One has been making significant contributions across various industries, showcasing its impact on research and development projects.<h3 dir="ltr">Advancing Solar Technology</h3>Researchers at The University of Akron used the V-One PCB printer to prototype modular solar (photovoltaic) shingles. Their goal was to create a more efficient manufacturing process using 3D printing and automated circuitry. By leveraging the V-One, they aimed to reduce both the cost and time required compared to traditional manufacturing methods. This innovative approach has the potential to make solar technology more accessible.<h3 dir="ltr">Eco-Friendly Supercapacitors</h3>At Tampere University, researchers utilized the V-One alongside additive manufacturing techniques to develop a functional supercapacitor. What sets this project apart is its focus on sustainability. The entire process used only environmentally safe and biodegradable materials. This achievement demonstrates the V-One's ability to drive green technology initiatives.<h3 dir="ltr">Aerospace Innovations with CubeSats</h3>The aerospace industry has also benefited from the V-One's capabilities. At Princeton University, the V-One was instrumental in <a href="https://www.voltera.io/customer-stories/princeton-university?utm_campaign=Wevolver&utm_source=Wevolver&utm_content=Princeton%20Customer%20Story" target="_blank">building CubeSats</a>—small, cube-shaped satellites used for space research. These miniature satellites are essential for studying various aspects of space and planetary science. The V-One’s ability to quickly produce PCBs helped streamline the development process, enabling Princeton’s research students to focus on innovation and experimentation.These partnerships not only showcase V-One's adaptability but also underscore its potential to accelerate research and development in advanced technological fields.<h1 dir="ltr" id="isPasted">Future-Proofing Your Prototyping Process</h1><h3 dir="ltr">How the V-One can be integrated into a larger prototyping workflow</h3>Incorporating the Voltera V-One PCB printer into a broader prototyping workflow can accelerate your product development process. By pairing the V-One with other prototyping tools like 3D printers, you can design and create PCBs along with enclosures or other mechanical parts in-house. This integrated approach not only saves time but also allows for rapid iteration and refinement of designs.<h1 dir="ltr">Conclusion</h1>The V-One speeds up the prototyping process significantly. With its ability to quickly print PCBs, drill vias, and dispense solder paste, you can iterate on designs in hours rather than days or weeks. By handling PCB prototyping in-house, the V-One cuts out costly third-party manufacturing and logistics expenses. It also helps protect your designs and intellectual property. Plus, its plug-and-play setup makes it easy to use and shortens the learning curve.Curious to see how the V-One can fit into your workflow? Book a call with the team at Voltera to explore how this innovative tool can meet your prototyping needs.<a href="https://meetings.hubspot.com/royperez/v-one-or-nova-demo?utm_campaign=Wevolver&utm_source=Wevolver&utm_medium=Book%20a%20meeting" target="_blank" rel="noopener noreferrer" class="button-main-action">Get in touch with the team</a>

Everything You Need to Know About Prototyping with the Voltera V-One: A Focus on Double-Sided PCBs

A Complete Guide to Prototyping Double-Sided PCBs in One Day

The transportation industry is rapidly evolving, driven by a global shift towards electrification. Ambitious climate goals and growing consumer demand for sustainability have made the electric vehicle (EV) market a center of innovation.In this evolving landscape, virtual prototyping has become vital for engineers, enabling more efficient and flexible EV development. While physical testing remains essential, its time and cost constraints can limit its effectiveness, making virtual prototyping indispensable for rapid, cost-effective design optimization.Virtual prototyping leverages predictive, real-time, and immersive simulation software, allowing engineers across domains to design, test, and validate vehicle components and systems in a digital, single-source environment before building any physical prototypes. It accelerates development, reduces costs, and fosters innovation by enabling rapid iteration and collaborative decision-making, particularly in exploring new designs, battery technology, and lightweight materials.Leading automakers such as Volvo, Toyota, SEAT, Renault, Toyoda Gosei, Hyundai, and Audi have embraced virtual prototyping in some capacity to stay competitive in this ever-evolving EV market and meet growing demands for sustainable, high-performance vehicles. This progressive approach enhances design efficiency and aligns with the industry's broader shift towards innovation.1<a href="https://www.esi-group.com/company/who-we-are" target="_blank">ESI Group</a>, a pioneer in this field, has been at the forefront of virtual prototyping since its first-ever crash simulation with Volkswagen in 1985. Today, ESI leads the field by setting new standards for virtual homologation, enabling automakers to validate their designs from the outset and eliminating the need for multiple costly and time-consuming physical prototypes for safety certification.This article provides an overview of how ESI's virtual prototyping solutions are transforming EV development.<h2 dir="ltr" id="isPasted">Overcoming Crash and Safety Testing Challenges</h2>Vehicle safety and structural integrity are critical in automotive design, especially for EVs. Simulation techniques are essential for analyzing crash dynamics, safety features, and overall performance. This approach allows designers to rapidly develop innovative solutions that meet evolving regulations and e-mobility challenges, ultimately leading to safer and more efficient vehicles.Here is how ESI's <a href="https://www.esi-group.com/products/virtual-performance-solution" target="_blank">virtual performance simulation</a> (VPS) software helps engineers tackle the most challenging cases in automotive engineering:<ul><li dir="ltr">Struggling with tight deadlines for testing crash scenarios?&nbsp;Test various scenarios in virtual crash simulation, including frontal, side pole, and far-side collisions, to evaluate vehicle deformation and its impact on occupants and pedestrians without the cost and delays of physical tests.2</li><li dir="ltr">Need to analyze complex airbag deployment? VPS accurately models and simulates airbag folding and deployment, including intricate side curtain airbags and non-uniform pressures, and is renowned for its unmatched accuracy and efficiency.3&nbsp;</li><li dir="ltr">Concerned about evaluating battery performance and safety early in development? Assess full car crash scenarios, regulatory crush analysis, and battery stiffness, shock, and swelling in crash and safety simulation to ensure designs meet rigorous safety standards before physical testing.4&nbsp;</li><li dir="ltr">Looking for a cost-effective way to assess vehicle strength and dynamics?&nbsp;Use ESI's single simulation tool to evaluate vehicle strength and dynamics, including stiffness, pothole impacts, door and hood durability, and the impact of water crossing. This enhances reliability while reducing testing mileage and material cost, making it more environmentally friendly.&nbsp;5</li></ul>In short, ESI's simulation software for virtual crash, safety, and structural testing enables you to effectively manage the complexities of modern vehicle design.However, another crucial aspect of vehicle performance engineering that demands just as much attention is vibro-acoustic performance.<h2 dir="ltr">Mastering Noise and Sound to Enhance EV Acoustics</h2>As vehicle electrification increases, managing acoustic comfort and compliance with noise regulations becomes increasingly crucial. Traditional acoustic testing may not address the complexities of new EVs, making virtual vibro-acoustic simulation a more comprehensive approach for optimizing interior and exterior noise.&nbsp;But how efficiently can you conduct vibro-acoustic analysis? Are you struggling to ensure a quiet, comfortable environment for passengers while meeting pass-by noise regulations and ensuring effective acoustic warning systems?Here's how ESI's <a href="https://www.esi-group.com/products/va-one" target="_blank">vibro-acoustic simulation software</a> can help you test and optimize interior and exterior noise performance, ensuring comfort, compliance and protection:<ul><li dir="ltr">Airborne Noise Simulation: Optimizes how noise control treatments affect cabin acoustics.</li><li dir="ltr">Structure-Borne Noise Analysis: Evaluates noise generated through structural loads.</li><li dir="ltr">Sound Package Design and Optimization: Designs and tests noise control countermeasures to enhance acoustic performance.</li><li dir="ltr">Pass-By Noise (PBN) Simulation: Ensures vehicles meet regulatory noise standards.</li><li dir="ltr">Acoustic Vehicle Alerting Systems (AVAS): Designs effective warning sounds to enhance safety.</li><li dir="ltr">Wind Noise: Predicts the effect of wind noise on acoustic comfort by integrating CFD data into the vehicle models.</li><li dir="ltr">Auralization: Creates realistic sound scenarios to evaluate the acoustic environment before physical testing.</li></ul><ul id="isPasted"><li dir="ltr">Road Noise Simulation: Predicts and optimizes noise levels from road interactions.6,7</li></ul> With safety and acoustic performance validated, the next step is manufacturability. Just as simulation software has transformed performance testing, manufacturing simulation enhances and optimizes production processes and part performance, ensuring the designs are realized with precision and efficiency.<h2 dir="ltr">Virtual Manufacturing for Lightweight Materials and Processes</h2>Lightweight materials are essential in modern vehicle body and chassis design as automakers seek to reduce weight for improved fuel efficiency and performance. This shift has led to a transition from only steel to multi-material strategies that combine steel with aluminum and composites such as carbon fiber.While these approaches reduce vehicle weight and maintain excellent crash performance, they also introduce new manufacturing challenges, necessitating the validation of the optimal combination of lightweight materials and joining processes to achieve the best performance-cost-weight ratio.To address these challenges, automakers should frontload their manufacturing decisions by creating a virtual manufacturing process chain. This approach provides early confidence in material selection, manufacturing methods, and assembly processes before physical production, reducing the risk of costly revisions and ensuring a smoother transition from design to manufacturing.&nbsp;ESI's <a href="https://www.esi-group.com/industries/automotive/body-chassis-manufacturing" target="_blank">multi-material assembly simulation</a> allows for thorough evaluation and optimization using the following virtual manufacturing simulation tools:<ul><li dir="ltr">ProCAST:&nbsp;Predicts and eliminates defects, such as misruns, inclusions, shrinkage porosity, cracks, and excessive distortions, in various casting processes, including large-scale or mega castings.8</li><li dir="ltr">PAM-STAMP:&nbsp;Virtually assesses defect formation, predicts and compensates for spring back in high-strength steels and aluminum, and explores advanced processes like press hardening.9</li><li dir="ltr">SYSWELD:&nbsp;Ensures robust, durable spot welds by predicting weld strength and quality. Analyze each assembly step, minimize distortions from gap closing and joining processes, and optimize weld sequences to control final assembly distortions.&nbsp;10</li><li dir="ltr">PAM-COMPOSITES:&nbsp;The only complete simulation chain that identifies and fixes manufacturing defects in composite products, covering draping, thermoforming, various resin molding processes, infusion, curing, and geometrical distortions.11</li></ul>However, developing sustainable, safe, and comfortable vehicles is just one part of the equation; integrating the human aspect from the early design stages is crucial for perfecting a new vehicle.This is where advanced immersive virtual reality (VR) software comes into play.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1ODg2NjA2Mzk0LUVTSV9MSVZFX0FVVE9fV2V2b2x2ZXJfMDJfODAweDUwMF92MDEuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib"> <h2 dir="ltr" id="isPasted">The Industrial Metaverse for Virtual Build and Immersive Product Integration</h2>Innovating in EV design and manufacturing introduces new risks that may not be apparent until production begins. These include components integration, assembly, installation or removal challenges, and maintenance issues.Without physical prototypes for early evaluation, these issues can lead to production bottlenecks and missed opportunities for optimization, impacting EV's overall success.ESI's <a href="https://www.esi-group.com/products/ic-ido" target="_blank">IC.IDO</a> (virtual reality software) offers an innovative solution, allowing automakers to experience their products within a collaborative industrial metaverse. It provides physically realistic virtual experiences for product assembly and maintenance, offering opportunities to:<ul><li dir="ltr">Evaluate&nbsp;space constraints, clearances, visibility, and component accessibility.</li><li dir="ltr">Assess and optimize&nbsp;cable and hose routing and handling.</li><li dir="ltr">Define and refine&nbsp;installation and removal paths.</li><li dir="ltr">Develop,&nbsp;test, playback, refine, and optimize assembly processes.</li><li dir="ltr">Validate&nbsp;procedures, work cells, and production lines.</li></ul>Identifying potential issues early with VR accelerates the development process, reduces costs, and improves the quality and safety of the final product. Therefore, automakers can optimize the entire product lifecycle from initial concept to final assembly by simulating real-world interactions with virtual prototypes.&nbsp;<h2 dir="ltr">Discover More EV Innovation at ESI LIVE Automotive</h2>To explore these fundamental simulation technologies in detail and gain valuable insights from leading experts, attend ESI LIVE Automotive. This event offers a comprehensive overview of predictive modeling and virtual prototyping through practical examples from the automotive industry.Attendees will learn about optimizing EV safety and comfort, mastering noise and sound, virtual manufacturing for lightweight materials, and the role of the industrial metaverse in virtual build and product integration.Discover how these technologies are advancing electric vehicle design. Join us to gain valuable insights from industry experts and stay up-to-date with the latest developments.What:&nbsp;ESI Live automotive digital eventWhen:&nbsp;October 24th, 2-4 PM CETRegister: Free to attend.&nbsp;<a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer" class="button-main-action">Sign up to attend here.</a>&nbsp;For more information and to register, visit <a href="https://www.wevolver.com/article/esi-live-automotive-digital-event-empowering-innovation-through-virtual-prototyping/draft" target="_blank" rel="noopener noreferrer">ESI LIVE Automotive</a>.<h3 dir="ltr">References</h3><ol><li dir="ltr">ESI Group. How is Virtual Prototyping Accelerating Electric Vehicle Development? [Online]. Available at: <a href="https://www.esi-group.com/ebook-how-is-virtual-prototyping-accelerating-electric-vehicle-development" target="_blank">https://www.esi-group.com/ebook-how-is-virtual-prototyping-accelerating-electric-vehicle-development</a>&nbsp;</li><li dir="ltr">ESI Group. Virtual Performance Solution - Software to Simulate &amp; Test Crash &amp; Safety. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/crash-and-safety" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/crash-and-safety</a>&nbsp;</li><li dir="ltr">Baccari, N. Toyoda Gosei Europe Cuts Lead Times in Half Using Virtual Prototyping. (2020). [Online]. Available at: <a href="https://www.esi-group.com/blog/toyoda-gosei-europe-cuts-lead-times-in-half-using-virtual-prototyping" target="_blank">https://www.esi-group.com/blog/toyoda-gosei-europe-cuts-lead-times-in-half-using-virtual-prototyping</a></li><li dir="ltr">ESI Group. Software to Simulate Battery Safety. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/battery-safety" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/battery-safety</a></li><li dir="ltr">ESI Group. Software to Simulate Strength &amp; Dynamics. [Online]. Available at: <a href="https://www.esi-group.com/products/virtual-performance-solution/strength-and-dynamics" target="_blank">https://www.esi-group.com/products/virtual-performance-solution/strength-and-dynamics</a></li><li dir="ltr">ESI Group. Simulation Software Solutions for Acoustic Performance. [Online]. Available at: <a href="https://www.esi-group.com/industries/automotive/simulation-software-solutions-for-acoustic-performance" target="_blank">https://www.esi-group.com/industries/automotive/simulation-software-solutions-for-acoustic-performance</a></li><li dir="ltr">ESI Group. VA One - Interior Acoustics Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/va-one/interior-acoustics-simulation-software" target="_blank">https://www.esi-group.com/products/va-one/interior-acoustics-simulation-software</a></li><li dir="ltr">ESI Group. ProCAST - Casting Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/procast" target="_blank">https://www.esi-group.com/products/procast</a></li><li dir="ltr">ESI Group. PAM-COMPOSITES - Composite Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/pam-composites" target="_blank">https://www.esi-group.com/products/pam-composites</a></li><li dir="ltr">ESI Group. SYSWELD - Welding &amp; Assembly Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/sysweld" target="_blank">https://www.esi-group.com/products/sysweld</a></li><li dir="ltr">ESI Group. PAM-STAMP - Stamping Simulation Software. [Online]. Available at: <a href="https://www.esi-group.com/products/pam-stamp" target="_blank">https://www.esi-group.com/products/pam-stamp</a>&nbsp;</li></ol>ESI Group. IC.IDO - Virtual Reality Engineering Software. [Online]. Available at: <a href="https://www.esi-group.com/products/ic-ido" target="_blank">https://www.esi-group.com/products/ic-ido</a>&nbsp;

Virtual prototyping is essential for efficient, flexible EV development, complementing physical testing to overcome time and cost constraints.

How to Drive Faster and More Collaborative Decision-Making for Next-Generation Vehicle Development

<a href="https://esiliveautomotive.vfairs.com/" target="_blank" rel="noopener noreferrer">ESI LIVE Automotive</a> is an event that’s dedicated to driving EV innovation through the power of virtual prototyping. Attend online on October 24th to discover how ESI’s cutting-edge simulation software supercharges design cycles, boosts efficiency, and ensures flawless manufacturability.Get ready to explore game-changing strategies for optimizing EV safety, comfort, and durability with the latest digital innovations. Dive into mastering EV acoustics, and see how virtual manufacturing is driving the shift towards lightweight materials. Take a step into the industrial metaverse where XR technology is redefining collaboration in design, manufacturing, and maintenance.&nbsp;Sign up for ESI LIVE Automotive and attend insightful panel discussions, hear inspiring customer stories, and grab a front-row seat to the future of the EV industry!<table style="width: 98%; margin-right: calc(2%);"><tbody><tr><td style="width: 100%;">What:&nbsp;ESI LIVE Automotive digital event When: October 24th, 2-4 PM CET Register: Free to attend.&nbsp;<a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer">Sign up to attend here.</a> </td></tr></tbody></table><h3 id="isPasted">Highlights of ESI LIVE: &nbsp;</h3><ul><li>Optimizing EV safety, comfort, and durability:&nbsp; &nbsp;Discover innovative strategies for ensuring safety compliance, enhancing seating design and pre-certification, and streamlining the design process of complex systems through cutting-edge digital solutions.</li><li>Mastering noise and sound-enhancing EV acoustics:&nbsp; &nbsp;Identify next-generation simulation methodologies and innovative design techniques come together to revolutionize acoustic performance in electric vehicles.</li><li>Virtual manufacturing for lightweight materials and processes: &nbsp;Learn how to find the most efficient materials and manufacturing processes to achieve assemblies with optimal cost/quality ratio, ensuring correct performance.</li><li>Industrial metaverse for virtual build &amp; immersive product integration: &nbsp;Explore how XR technology breaks silos, fostering collaboration between design, manufacturing, and maintenance teams.</li></ul>Take advantage of this opportunity to hear customer stories, engage in insightful panel discussions, and witness firsthand the transformative capabilities of Virtual Prototyping in shaping the future of EV industry solutions.&nbsp;<a href="https://esiliveautomotive.vfairs.com/en/#agenda" target="_blank" rel="noopener noreferrer" class="button-main-action">Check out the agenda below.</a><table border="1" cellspacing="0" cellpadding="0" width="600" id="isPasted"><tbody><tr><td width="100%" colspan="3" valign="top">ESI LIVE AUTOMOTIVE 2024 AGENDA</td></tr><tr><td width="19%" valign="top">Date &amp; Time</td><td width="30.833333333333332%" valign="top">Track theme</td><td width="50.166666666666664%" valign="top">Details</td></tr><tr><td width="19%" valign="top">October 24, 02:00 pm CET</td><td width="30.833333333333332%" valign="top">Optimizing EV safety, comfort, and durability.&nbsp;</td><td width="50.166666666666664%" valign="top">The sessions cover key topics in automotive design and compliance. The first session discusses maintaining safety regulations and optimizing vehicle design within virtual homologation. The second session focuses on the effective design, manufacturing, testing, and pre-certification of vehicle seating. The final session explores the use of a digital thread in the design process of complex systems.</td></tr><tr><td width="19%" valign="top">October 24, 02:00 pm CET</td><td width="30.833333333333332%" valign="top">Empowering EV innovation: virtual manufacturing for lightweight materials and processes.&nbsp;</td><td width="50.166666666666664%" valign="top">The sessions focus on advancements in electric mobility and lightweight materials. The first session addresses the use of manufacturing simulations to evaluate performance in mega-casting components for electric vehicles. The second session discusses the challenges of using lightweight aluminum for stamping Class A panels. The final session covers innovative, high-efficiency components designed for electric and hydrogen vehicles.</td></tr><tr><td width="19%" valign="top">October 24, 02:00 pm CET</td><td width="30.833333333333332%" valign="top">Industrial metaverse for virtual build &amp; immersive product integration.&nbsp;</td><td width="50.166666666666664%" valign="top">The sessions explore integrating advanced virtual and immersive technologies in mobility and product development. The first session discusses how extended reality is shaping the future of mobility today. The second session focuses on enterprise virtuality and collaborative virtual builds. The final session examines human-centric process validation and immersive product integration.</td></tr></tbody></table><h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1ODgzNDMxMDY1LXBkZi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></h3><h3 id="isPasted">Why you should attend:&nbsp;</h3>Attending ESI LIVE Automotive offers a unique experience for professionals in the automotive industry, particularly those focused on electric vehicle (EV) development. Participants will have the chance to engage with thought leaders, network with peers, and gain insights into the latest advancements in EV design, manufacturing, and sustainability.&nbsp;By attending, you'll not only stay ahead of industry shifts but also contribute to the critical conversations that are driving the electric vehicle revolution. This event is more than just an opportunity to learn—it's a chance to collaborate on groundbreaking ideas that will define the next era of mobility. Your presence and participation will help push the boundaries of what's possible, empowering innovation and fostering a sustainable transportation future.We look forward to seeing you there, as together, we can make a significant impact on the future of automotive technology and sustainable mobility.<h3>More details</h3>To attend the ESI Live Automotive event, <a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer">register here</a> - the event is free.&nbsp;<a href="https://esiliveautomotive.vfairs.com/en/registration?utm_source=wevolver&utm_medium=all&utm_campaign=registration" target="_blank" rel="noopener noreferrer" class="button-main-action">Register here.</a>The vFairs platform used for the event is accessible from any device or browser. If you have any questions, you can email event@esi-group.com.&nbsp;We encourage you to share the registration link with others who may benefit from the event. Your registration information will be used to create your login credentials and follow up. For more details, you can check the <a href="https://www.esi-group.com/privacy-terms-of-use" target="_blank" rel="noopener noreferrer">terms and conditions.</a>

Register for the live event, October 24th, 2-4 PM CET


ESI LIVE automotive digital event: Empowering innovation through virtual prototyping

<h2 id="isPasted">New whitepaper: How Augmented Reality is redefining product development.</h2>Augmented Reality (AR) is not just a tool; it's a transformative force that is reshaping many processes in business. Production companies, in particular, benefit from AR because they can leverage its benefits along their entire value chain, from product development to manufacturing, logistics, marketing, customer service, and employee training.&nbsp;In the recent white paper from HoloLight, 'AR as a Booster for Industry 4.0,' you can explore the ways in which AR can have a significant transformative impact.&nbsp;Key highlights of the whitepaper:<ul><li dir="ltr">Learn how companies can use AR to increase the quality and productivity of their entire process chain</li><li dir="ltr">Understand what a consistent Augmented Reality strategy can look like and how to implement one.</li><li dir="ltr">Discover how well-known companies are already successfully using AR through detailed case studies.&nbsp;</li></ul>Don't miss out on these valuable insights. Get your copy of the white paper now by filling out the simple form below.&nbsp;<iframe id="JotFormIFrame-241713238748360" title="Hololight Form" allowtransparency="true" src="https://form.jotform.com/241713238748360" frameborder="0" style="min-width:100%;max-width:100%;height:539px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"> </iframe><a href="https://hololight.com/lns-group-saves-prototyping-costs-for-machine-tools/" target="_blank" rel="noopener noreferrer">LNS Group</a>, a Swiss leader in machine tool peripherals, is driving immersive technologies throughout its product development cycles. From early design reviews with global stakeholders to risk assessment and handover to operations, the company is reducing time-to-market by 3 months and saving $5,000 to $10,000 per prototype while improving product quality.LNS Group is a global Swiss machine tool peripherals specialist that operates four different product lines and has nine production sites across Switzerland, Italy, the UK, Taiwan, China, Japan, and the USA. The company has around 1,000 dedicated professionals worldwide and is known for its strong focus on research and development as well as its global presence. “The way we communicate is key to the success of the product,” emphasizes Jamie Towers, CTO of LNS. “You can’t really quantify it, but the most important thing in product development is to get buy-in from all the stakeholders and have everyone understand and agree on what we’re trying to accomplish as early as possible.”Easier said than done. The CTO and the innovation team recognized the early need to integrate industrial augmented and virtual reality (AR/VR) into their research and development processes to encourage better communication and collaboration among global teams and departments. “We chose the XR Engineering solution, <a href="https://hololight.com/" target="_blank" rel="noopener noreferrer">Hololight Space</a>, because it met our vision for adaptability and ease of use right from the start. We upload our designs to the cloud platform and simply start a collaborative meeting. In our industry, complexity often leads to resistance, but the solution’s straightforward functionality means our team can focus on pushing the boundaries of innovation without the frustration of dealing with cumbersome systems.”<h2>How LNS Group Engages Non-Design Teams with Augmented Reality for Better Outcomes</h2>LNS specializes in manufacturing bar feeders, chip conveyors, air filtration, and coolant management systems, &nbsp;essential for the automotive, watch, medical, and aerospace industries. The company follows a standard product development process. They start by reviewing market requirements, then proceed to the development phase, and finally return to the market for implementation.. “We’re 100% committed to delivering customer-focused products,” says Towers. “The only way to do that is to really work with the customer and the people who face the customer. That’s your sales team, that’s your customer service team. And those are the hardest people to engage when it comes to design reviews,” he adds with a smile.Non-design teams often struggle with the challenge of visualizing products from onscreen models alone. The difficulty of assessing scale, accessibility, and maintenance considerations from a 3D model on a 2D screen can create a gap in understanding the product in tangible terms, making it difficult to provide the concrete feedback engineers need to better tailor the product to customer needs. This gap often requires the creation and global distribution of multiple prototype versions, at significant financial and environmental cost. Hololight Space now provides a dynamic digital workspace for seamless interaction with 3D CAD data in both AR and VR environments. Users can visualize and work with their 3D content to review designs, plan a factory layout, perform quality assurance, or verify assembly processes. Data is streamed from powerful on-premises or cloud servers with Nvidia GRID GPUs to ensure high levels of security and high-quality visualization without the need for data optimization.<iframe width="640" height="360" src="https://www.youtube.com/embed/pX3jw1FnRyw?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> <h3>Use Case 1 – How LNS Group Uses AR for Worldwide Collaboration &amp; Design Reviews</h3>Using Hololight Space in the design process heralds a transformative shift. Teams can visualize products in real-world contexts, facilitating more accurate and comprehensive early-stage reviews. Tangible interaction with a product before it is physically created, leads to the development of more accurate initial prototypes, significantly shortening the iterative cycle of prototyping. “Visualizing our designs in AR and the real world helps us get valuable feedback from our sales and customer service teams on what might need to be tweaked to better meet customer needs. It also works very well with our customer service teams, such as checking the accessibility on the digital twin to see how we can service a particular product,” explains Brian Scruggs, Global Engineering Administrator at LNS. “We typically use Hololight Space to highlight key features that we need specific feedback on, and then everyone can look at the design together, we take notes, and we also use the live stream so everyone can follow along.”Including AR in the design review process not only improves communication but also enhances buy-in from stakeholders. “We are able to get products from the drawing board to market in a short period of time – from large developments with many stakeholders to smaller projects with small groups,” notes Scruggs. By removing the barriers to visualization, AR reduces the number of prototypes needed, thereby lowering costs and minimizing environmental impact. In addition, effective design reviews cultivate company-wide support, reducing the frustration often associated with late-stage design changes. “The ease of use is a critical point, having the backup and support behind it is also a key, and frankly the price point is right for what we need. For us, using Hololight Space is now like turning on a computer. It is second nature to us,” concludes Scruggs.<h2>Use Case 2 – How LNS Group Masters CE Compliance and Risk Assessment Across Borders</h2>Leveraging its global R&amp;D network, LNS usually designs products in one region and manufactures them in another.. The company manages CE compliance from Switzerland with the help of external consultants. This is an important step in the product development process and is often performed, along with a risk assessment, near the end of the prototyping phase.. “Changes – and there are almost always changes – can have a profound impact on the design, cost and overall concept of the product. As a result, compliance assessments introduced later in the process can add significant time to the schedule,” states Jamie Towers, CTO of LNS. “We were looking for a way to do risk assessment earlier in the design process, before we even built a prototype, not only internally but also with our external consultants.”Global Engineering Administrator Brian Scruggs elaborates, “To give an example, we had a project in China with a large machine tool manufacturer where the product would end up in Europe and instead of shipping a product to Switzerland, we decided to use Hololight Space to do a remote risk assessment with our external consultant. We did the risk assessment in Augmented Reality, discovered some changes that needed to be made, and were able to fix the mistakes before we ever built and shipped a product to Europe.” By avoiding shipping, travel, and building a prototype, LNS was able to save $5,000 to $10,000, while significantly reducing the environmental costs associated with building multiple prototype iterations. “We saved at least three months of project time by conducting early risk assessments and avoiding the need for later “patches” to the design,” reports Scruggs. “The result is not only a reduction in time and cost, but also a product that truly meets the practical considerations of the user.”<h2>Use Case 3 – How LNS Group Streamlines Operations Handover with Industrial Augmented Reality</h2>Finally, “handover to operations” is a pivotal moment. It’s the critical transition where all the plans, prototypes, and theoretical work are handed over to the teams that will implement them in the real world. Early involvement of the operations team is a good starting point for a successful handover. However, understanding complex operations from afar often leads to early production problems, and the travel costs of sending experts to different production sites can be significant.. In addition, internal frustration can result from a lack of understanding and cooperation during this crucial transition period, leading to delays and low morale. “I think it’s important to understand that there is usually some form of compromise when design changes are introduced late in the process,” says Scruggs.&nbsp;He adds: “For us, it’s about improving quality down to every sub-assembly. With Hololight Space, our operations teams in different regions can see in Augmented Reality how each assembly is created in real time. They can see the critical points and we can identify where there may be mistakes or confusion; it’s a collaborative effort to get better quality from day one, using immersive technologies to our advantage.” By enabling better collaboration across sites and geographies, AR improves the quality and speed of production ramp-up, ensuring a smoother transition from design to operation. The ability to work remotely with AR technology, especially when multiple international locations are involved, greatly reduces travel-related costs and time. In an era where efficiency and communication are paramount, Hololight Space is proving to be a key tool in transforming the handover of operations into a seamless and streamlined process.<h2>How LNS Group Is Getting User Buy-in and Planning New Use Cases</h2>To successfully integrate Augmented Reality into the product development process and gain user acceptance, Jamie Towers suggests limiting user interaction. &nbsp;“We usually have an AR-trained member in the room to help with the manipulations, and then we hand the glasses over to the user to just experience the design in AR. There are some people who are never fully comfortable until they actually have something in their hands. But overall, our people are definitely impressed with the technology. They see the value in the technology.”And the next project is just around the corner. “We’re investing in immersive technologies, and it’s natural to keep using them. This time we made a prototype with one configuration, and we’re going to use Hololight Space to show our customer a second, completely different configuration without having to produce a second prototype. Wherever we can find an advantage, we will use immersive technologies to optimize our product development lifecycle,” concludes Towers.Want to try Hololight Space for yourself? <a href="https://hololight.com/hololight-space-demo/" target="_blank">Contact us for a free trial.</a>

LNS Group, is using immersive technologies throughout its product development cycles. The company is reducing time-to-market by 3 months and saving $5,000 to $10,000 per prototype while improving product quality.
